Author: Win Zhang Publish Time: 2025-10-29 Origin: Jinan Shilai Technology Co., Ltd.
Short answer:
There’s no one-size-fits-all approach to cutting gasket materials. Graphite demands abrasion-resistant blades and aggressive dust control. PTFE needs cool, clean cuts with tight kerf management. Elastomeric rubbers require anti-lift strategies and tuned oscillation. Start with proven baselines—but always validate on your machine, with your material, and lock in recipes that work.
Gasket converters looking to boost yield, improve edge quality, and reduce scrap
OEMs bringing gasket cutting in-house across multiple material types
Process engineers setting up SPC controls or standardizing digital cutting recipes
Procurement teams evaluating CNC digital knife systems for multi-material flexibility
Jump to your material: Start with the section that matches your current job—Graphite, PTFE, or Rubber.
Apply baseline settings: Use the recommended parameters as a starting point—not a final answer.
Run trials: Cut test parts on your machine, measure critical features, and fine-tune feed, amplitude, depth, and kerf.
Save what works: Lock successful combinations into named “recipes” tied to material, thickness, and adhesive stack.
Brittle and prone to edge crumbling under excessive force
Highly abrasive—wears blades faster than most gasket materials
Generates fine, conductive dust that demands extraction
Common forms: plain, foil-reinforced (SS tanged), or adhesive-backed with release liners
Primary: Tungsten-carbide oscillating knife (sharp tip, slight tilt tolerance)
Alternative: Hard-coated drag knife for simple outlines at lower speeds
For tiny holes: Micro-punch to avoid chipping
Marking: Inkjet or pen—avoid mechanical scribing (creates dust)
Use strong, zoned vacuum with a carrier sheet for small parts
Place a dense sacrificial underlay (e.g., specialized cutting mat or felt)
Add micro-tabs to prevent fly-out on intricate features
Oscillation: 10,000–14,000 strokes/min (slice, don’t pry)
Amplitude: Low to medium (minimizes breakout)
Feed rate: around 100mm/min
Step-down: Full depth for plain graphite; consider two passes for thick or foil-laminated stock
Corners: Decelerate; use slight overcut for sharp internal corners
Kerf compensation: 0.10–0.25 mm (calibrate as blade wears)
Blade life: Short—inspect frequently; graphite dulls edges fast
Inspect edges under magnification for delamination or crumbling
Monitor ID/OD dimensions—tolerance drift signals blade wear
Maintain dust extraction: clean filters, protect linear guides
Use common-line cutting with AI-powered nesting to reduce kerf loss
Schedule frequent blade changes—dull blades cost more in rework than in tooling
Maintain separate kerf libraries for “new,” “mid-life,” and “end-of-life” blades
Low stiffness and prone to creep—edges smear if cut too fast or hot
Filled grades (glass, carbon, graphite) are stiffer and mildly abrasive
ePTFE is soft, porous, and easily pulled into vacuum zones
⚠️ Avoid lasers—PTFE releases toxic fumes when thermally cut.
Primary: Sharp, polished-edge oscillating knife (fine tip)
For thin films: New drag knife—dull blades cause burrs
No heat sources: Stick to cold mechanical cutting
Uniform, consistent vacuum across the bed
Use a carrier sheet for thin or ePTFE to prevent pull-through
Replace underlay regularly to maintain consistent cutting depth
For PSA-backed PTFE: Ensure rigid liner support during kiss-cutting
Oscillation: 8,000–12,000 strokes/min
Amplitude: Low (prevents lip or feathering)
Feed rate: around 100mm/min (slower for filled or thick stock)
Multi-pass: Recommended for >2 mm thickness to reduce deformation
Corners: Aggressive deceleration + small radius compensation
Kerf compensation: 0.08–0.20 mm (verify on small holes)
Kiss-cut depth: Calibrate per job—aim for liner mark without breach
Look for edge feathering—reduce feed or amplitude if present
Measure narrow bridges and small IDs; adjust path order if needed
Perform peel tests: clean release, no liner tear
Apply rotation constraints in nesting for skived PTFE (grain direction matters)
Digitally track remnants—many PTFE parts are small and ideal for offcut reuse
Control shop temperature—PTFE expands/contracts noticeably with heat
Elastic and tacky—tends to lift with the blade, especially at corners
Softer grades (e.g., silicone, low-durometer EPDM) are more prone to distortion
May include fabric reinforcement or pressure-sensitive adhesive (PSA)
Primary: Oscillating knife with tip angle matched to durometer
Secondary: Drag knife for firm, thin rubbers with simple profiles
For tight bolt patterns: Micro-punch on soft, thick sheets
Maximize vacuum coverage—use zoned control for mixed layouts
For soft silicones or foams: add carrier sheets and micro-tabs
Switch to denser underlay for precise kiss-cut depth control
Oscillation: 10,000–15,000 strokes/min
Amplitude: Medium (ensures clean shear through elastic material)
Feed rate: around 200mm/min (slower for soft or thick FKM/silicone)
Corners: Significant deceleration + short overcuts to prevent shape change
Path strategy: Cut internal features first; use anti-lift sequencing
Kerf compensation: 0.10–0.25 mm (validate by hardness and blade type)
Kiss-cut: Run depth calibration per batch; use test squares
Check for burrs or whiskers—sharpen blade or increase oscillation
Account for elastic recovery: holes may shrink slightly post-cut
Confirm small parts stay in place—adjust vacuum release timing if needed
Common-line cutting can cut kerf loss in half—just verify hold-down first
Build recipe libraries by durometer and thickness to reduce setup time
For premium materials like FKM, even 5–10% yield gains significantly impact ROI
Depth tolerance must be ±0.05 mm or better to avoid cutting the liner
Adhesives can gum up blades and degrade edge finish
Use sharp, low-friction blades—coated edges help with sticky adhesives
Rigid liner support + clean, flat underlay (rotate frequently)
Add vision registration if cutting pre-printed or registered graphics
Depth calibration: Per material, per zone—compensate for mat wear
Feed rate: Slightly slower than through-cuts
Oscillation: Lower amplitude to avoid scuffing the liner
Path order: Cut internal features and labels first; perimeter last
Perform peel tests at multiple locations—no liner breaches
Clean blades regularly; schedule quick wipes during long runs
Print part IDs inline for full traceability
Holes <5 mm or thin webs: Use micro-punch, increase vacuum zoning, slow feed, boost oscillation
Realistic tolerances:
±0.1–0.2 mm on stable materials (graphite, filled PTFE)
±0.3–0.5 mm on foams or soft silicones
For SPC: Track kerf per job, log blade life, monitor vacuum pressure—and maintain separate recipes if material batches vary
Respect grain direction: Apply rotation constraints for skived PTFE or laminated graphite
Common-line cutting: Use on uniform materials—but add bridge tabs to retain micro-parts
Remnant management: Barcode offcuts; let your nesting software auto-suggest remnant reuse
Key KPIs:
Yield %
Cycle time per m²
Scrap disposal cost (especially critical for PTFE and graphite)
Blade care: Log meters cut per blade; replace early on abrasive or PSA jobs
Underlay: Rotate and replace on schedule—depth consistency affects kiss-cut accuracy
Dust control: Service filters and debris traps regularly; use local extraction for graphite
Backups: Save tool libraries, kerf tables, and nesting templates before firmware updates
Before locking in a recipe:
Send your CAD files and material samples to your equipment vendor
Request sample cuts with:
Measurement reports (IDs/ODs, small features)
Edge close-ups
Kiss-cut peel test results
Run a nesting yield comparison on your top 3–5 SKUs
Freeze winning settings into operator-locked recipes
Train operators on recipe selection and basic verification
Material | Thickness | Oscillation (spm) | Amplitude | Feed (mm/min) | Kerf Comp (mm) | Notes |
Graphite | 1–3 mm | 10k–14k | Low–Med | 300–600 | 0.12–0.22 | Watch for dust & edge crumble |
PTFE (virgin) | 1–2 mm | 8k–12k | Low | 250–500 | 0.10–0.18 | Consider 2-pass for clean edges |
Filled PTFE | 1–2 mm | 9k–12k | Low–Med | 200–450 | 0.10–0.20 | Slower feed for glass-filled |
NBR/EPDM | 2–5 mm | 10k–15k | Med | 500–900 | 0.12–0.25 | Anti-lift pathing essential |
Silicone | 2–5 mm | 10k–14k | Med | 400–800 | 0.12–0.25 | Extra corner decel needed |
Note: “spm” = strokes per minute. Units vary by machine—match to your system’s terminology. Always validate locally.
We build CNC digital cutting systems engineered specifically for gasket manufacturing—handling everything from abrasive graphite and slippery PTFE to elastic rubbers and multi-layer PSA stacks. Our platforms support oscillating and drag knives, vision registration, fixed or conveyor tables, and open-architecture software—so you can standardize recipes, maximize yield, and lock in quality.
Ready to test your materials?
Send us your CAD files and sample sheets. We’ll provide live cuts, measurement reports, kiss-cut validation, and a tailored ROI analysis—no obligation.
